Junction box and conductor strip connection device thereof

ABSTRACT

A conductor strip connection device for a junction box of a solar module is disclosed and comprises a contact member having a contact segment for connecting to a conductor strip, a carrier member, and a lever pivotally connected with the carrier member and having a suppressing portion, wherein the suppressing portion is configured to cooperate with the contact segment of the contact member for disposing or removing the conductor strip when the lever is switched toward a first position and clamping and fastening the conductor strip when the lever is switched toward a second position.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of prior U.S. provisional application 61/383,812, which is entitled “CONNECTION OR JUNCTION BOX” and filed on Sep. 17, 2010. The entire disclosures of the above-captioned application are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to a junction box, and more particularly to a junction box for solar module and a conductor strip connection device thereof.

BACKGROUND OF THE INVENTION

There are several advantages of photovoltaic solar power that make it one of the most promising renewable energy sources in the world. The photovoltaic solar power is free, needs no fuel and produces no waste or pollution, and the solar power generator requires little maintenance and no supervision and has a life of 20-30 years with low running costs. Solar power generators are simply distributed to homes, schools, or businesses, where their assemblies require no extra development or land area and their functions are safe and quiet. Remote areas can easily produce their own supply of electricity by constructing as small or as large of a system as needed.

Generally, the solar or photovoltaic module for generating electric energy from sunlight comprises a plurality of solar or photovoltaic cells. The solar cells in a solar module are usually connected to each other by thin conductor strips (i.e. conductor ribbons). These thin conductor strips are routed out of the solar module on the side facing away from the sun. The thin conductor strips are mostly made of copper foils and protruded from the rear side of the solar module (i.e. solar panel). These flexible and thin conductor strips are very sensitive and difficult to contact. Therefore, one or more junction boxes are employed for the solar module and thin conductor strips are manually contacted with electrical terminal receptacles of the junction box. In addition, the junction box is an integral part of a solar or photovoltaic system and it provides electrical connections between the solar cells of the individual solar module (i.e. solar panel) and between the solar modules and other components of the system (i.e. DC/AC inverter). Generally, the junction box is disposed on a rear surface of the solar panel and has electrical connection mechanism in the interior for contacting the thin conductor strips of the solar modules and conducting the electrical current generated by the solar modules to the outside. Without a junction box, the solar modules could not work properly.

Generally, plural solar modules are operated in series connection, wherein a so called bypass diode is anti-parallel connected to each solar module. The bypass diode is disposed inside the junction box and fastened and connected to the electrical connection mechanism of the junction box. In a case of a solar module is shaded or does not produce electricity because of defect, this solar module would lower the power of the solar modules in series connection or even suffers damage without bypass diode. This is because that if a solar cell within a solar cell group of the solar module is partially shaded, this shaded solar cell acts as a blocking diode or resistor within the circuit of the solar cell group, which may result in a damage of the shaded solar cell and result in the entire solar cell group of the solar module no longer being able to supply electric energy. The above-mentioned situations can be avoided by using the bypass diode of the junction box, because the current flows through the diode and is sustained. In other words, the bypass diodes are electrically connected in an anti-parallel manner with respect to the solar cell groups and have the effect that the current flow through the solar module is led past solar cell groups that only supply low power, i.e. the terminals of this solar cell group of a solar module are short-circuited by the bypass diode and the corresponding cell group is bypassed thereby. Thus, such a solar cell group does no longer contribute to the overall performance of the solar module, but the overall current flow through the solar panel is substantially unobstructed and a damage of individual solar cell is avoided.

It is obviously that due to the mechanical conditions particularly the form of the thin conductor strips and the bypass diodes, a number of difficulties occur when constructing the junction box. In addition, due to the manual connecting, the assembly and installation of the thin conductor strips and the bypass diodes with the electrical connection mechanism inside the junction box is cost and laborious. Up to now, the conventional junction box is complex in construction and installing the junction box is laborious. In addition, the conventional junction box doesn't provide reliable electrical connections and the durability of the junction box is low. It is therefore desirable to provide a junction box that is simple in structure, cost-effective, durable enough to withstand a wide range of environment conditions and easily be installed and maintained, while maintaining a high-quality, reliable electrical connections between the components of a solar or photovoltaic system.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a junction box with a conductor strip connection device capable of assembling, fastening and coupling the thin conductor strips of the solar module to the junction box easily.

It is another object of the present invention to provide a junction box with a conductor strip connection device capable of assembling, fastening and coupling the thin conductor strips of the solar module to the junction box without using auxiliary tool or screwdriver.

It is another object of the present invention to provide a junction box for solar modules, which is simple in construction, cost-effective, durable enough to withstand a wide range of environment conditions and easily be assembled, installed and maintained.

It is still an object of the present invention to provide a junction box for solar modules, which can maintain a high-quality, reliable electrical connections between the components of a solar or photovoltaic system.

In accordance with one aspect of the present invention, a junction box comprises a housing having an opening for introducing a plurality of conductor strips, and an electrical connection mechanism disposed in a receptacle of the housing. The electrical connection mechanism comprises a plurality of conductor strip connection devices separately disposed on an inner surface of the housing for connecting to the conductor strips, and a current-path arrangement module comprising a plurality of electricity conveying elements and a plurality of electronic components, wherein the electricity conveying elements are connected with the conductor strip connection devices respectively, and each electronic component is connected with two adjacent electricity conveying elements. Each of the conductor strip connection devices comprises a contact member having a contact segment, a carrier member, and a lever pivotally connected with the carrier member and having a suppressing portion, wherein the suppressing portion is configured to cooperate with the contact segment of the contact member for disposing or removing the conductor strip when the lever is switched toward a first position and clamping and fastening the conductor strip when the lever is switched toward a second position.

In accordance with another aspect of the present invention, a conductor strip connection device for a junction box of a solar module comprises a contact member having a contact segment for connecting to a conductor strip, a carrier member, and a lever pivotally connected with the carrier member and having a suppressing portion, wherein the suppressing portion is configured to cooperate with the contact segment of the contact member for disposing or removing the conductor strip when the lever is switched toward a first position and clamping and fastening the conductor strip when the lever is switched toward a second position.

The above contents of the present invention will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed description and accompanying drawings, in which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view showing a junction box for solar modules according to a preferred embodiment of the present invention;

FIG. 2 is a schematic view showing an electrical connection mechanism of the junction box of FIG. 1;

FIG. 3A a schematic view showing the conductor strip connection device of the electrical connection mechanism of FIG. 2;

FIG. 3B is an exploded diagram of the electrical connection mechanism of FIG. 3A;

FIG. 3C a schematic view showing the mechanism of the conductor strip connection device and the housing;

FIGS. 4A and 4B are schematic views showing the operation of the conductor strip connection device of FIGS. 3A and 3B; and

FIG. 5 is a schematic view showing the current-path arrangement module of the electrical connection mechanism of FIG. 2.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this invention are presented herein for purpose of illustration and description only. It is not intended to be exhaustive or to be limited to the precise form disclosed.

Please refer to FIG. 1, which is a schematic view showing a junction box for solar modules according to a preferred embodiment of the present invention. The junction box 1 of the present invention includes a housing 10 made of durable plastic that can stand the external weather influences for at least 20 years and has electrical insulation properties. The housing 10 includes a base 101 and a cover 102, which is detachably fastened to or engaged with the base 101. The housing 10 has at least one opening formed on the bottom of the base 101 for introducing the conductor strips of the solar modules into the interior of the housing 10. The housing 10 of the junction box 1 can be fixed or attached to the rear surface of the solar module (not shown in FIG. 1).

FIG. 2 is a schematic view showing an electrical connection mechanism of the junction box of FIG. 1. As shown in FIG. 2, the junction box 1 includes an electrical connection mechanism 11 disposed in a receptacle 103 of the base 101 and configured to connect with the conductor strips 2 of the solar modules through the opening 101 a of the base 101 and two electrical cables 3. The electrical connection mechanism 11 includes a plurality of conductor strip connection devices 12 and a current-path arrangement module 13, which is detachably connected with the conductor strip connection devices 12 and the electrical cables 3. The conductor strip connection devices 12 are separately disposed and mounted on an inner surface of the base 101 and configured to contact and connect with the conductor strips 2 of the solar modules, for example four flat and thin conductor strips 2 a, 2 b, 2 c, 2 d.

FIG. 3A a schematic view showing the conductor strip connection device of the electrical connection mechanism of FIG. 2. FIG. 3B is an exploded diagram of the electrical connection mechanism of FIG. 3A. As shown in FIGS. 2, 3A and 3B, each of the conductor strip connection devices 12 includes a contact member 121, a lever 122, a carrying member 123, a resilient member 124 and a shaft 125. The contact member 121 is made of metal material and includes a contact segment 1211, a fixing segment 1212 and a stopper 1213. The contact segment 1211 is configured to contact with a conductor strip 2 of the solar module. The fixing segment 1212 is configured to connect with a corresponding electricity conveying device of the current-path arrangement module 13. The fixing segment 1212 includes a through hole 1212 a and a leg 1212 b extending downwardly. The stopper 1213 is configured to limit the horizontal movement of the conductor strip 2 when the conductor strip 2 is inserted or plugged into the conductor strip connection device 12. Preferably, the stopper 1213 is a protrusion element extending upwardly from the contact segment 1211.

The lever 122 comprises a suppressing portion 1221, a handle 1222 and a shaft receiving portion 1223. The suppressing portion 1221 is configured to cooperate with the contact segment 1211 of the contact member 121 for clamping and fastening the conductor strip 2 of the solar module. Preferably, the suppressing portion 1221 is substantially vertical to the handle 1222, but it is not limited thereto. The shaft receiving portion 1223 is connected between the suppressing portion 1221 and the handle 1222, and the shaft receiving portion 1223 has a receptacle 1223 a for receiving the shaft 125.

The carrying member 123 includes a first sidewall 1231, a second sidewall 1232, a bottom plate 1233 connected with the first sidewall 1231 and the second sidewall 1232, and a receiving space 1234 defined by the first sidewall 1231, the second sidewall 1232 and the bottom plate 1233. The first sidewall 1231 and the second sidewall 1232 include a first through hole 1235 and a second through hole 1236 for installing the shaft 125. Two free ends of the shaft 125 are extended outwardly from the first sidewall 1231 and the second sidewall 1232 through the first through hole 1235 and the second through hole 1236.

The resilient member 124 is disposed between the contact segment 1211 of the contact member 121 and the bottom plate 1233 of the carrying member 123 for urging against the carrying member 123. The resilient member 124 includes a connection segment 1241, a first side segment 1242 and a second side segment 1243 opposite to the first side segment 1242. The first side segment 1242 and the second side segment 1243 are extending upwardly or downwardly from two opposite sides of the connection segment 1241.

The lever 122 is pivotally connected with the carrying member 123 by installing the shaft 125 through the shaft receiving portion 1223, the first through hole 1235 and the second through hole 1236 so that the lever 122 can be rotated and switched between a first position (as shown in FIG. 4A) and a second position (as shown in FIG. 4B). The suppressing portion 1221 of the lever 122 is disposed between the shaft 125 and the contact segment 1211 of the contact member 121. When the lever 122 is switched and rotated toward the first position, a gap is formed between the suppressing portion 1221 and the contact segment 1211 of the contact member 122 so that the conductor strip 2 of the solar module can be inserted into the gap. When the lever 122 is switched and rotated toward the second position, the suppressing portion 1221 and the contact segment 1211 of the contact member 121 clamp the conductor strip 2 of the solar module so that the conductor strip 2 of the solar module can be secured in the conductor strip connection device 12.

FIG. 3C a schematic view showing the mechanism of the conductor strip connection device and the housing. As shown in FIGS. 3A, 3B and 3C, the base 101 of the housing 10 further includes a plurality of holding devices 104 for installing the conductor strip connection devices 12 therein. The base 101 of the housing 10 further includes a supporting element 105 formed on an inner surface of the base 101 and disposed inside the holding device 104. The carrying member 123 includes a first slot 1237 formed in the bottom plate 1233, and the resilient member 124 includes a second slot 1244 formed in the connection segment 1241 and corresponding to the first slot 1237 of the carrying member 123. The supporting element 105 is passing through the first slot 1237 and the second slot 1244 and contacts with the rear surface of the contact segment 1211 of the contact member 121 so as to support the contact segment 1211 of the contact member 121 and prevent the deformation of the contact member 121.

FIGS. 4A and 4B are schematic views showing the operation of the conductor strip connection device of FIGS. 3A and 3B. As shown in FIGS. 3A, 3B, 3C, 4A and 4B, when the user wants to assemble and connect the conductor strips 2 with the junction box 1, the user can push the handle 1222 of the lever 122 for allowing the lever 122 to be rotated and switched toward the first position (as shown in FIG. 4A). When the lever 122 is rotated and switched toward the first position, the suppressing portion 1221 of the lever 122 is apart from the contact segment 1211 of the contact member 121 and the resilient member 124 contacts the bottom plate 1233 of the carrying member 123 so that a gap g is formed between the suppressing portion 1221 of the lever 122 and the contact segment 1211 of the contact member 121. Therefore, one conductor strip 2 can be inserted into the gap g between the suppressing portion 1221 of the lever 122 and the contact segment 1211 of the contact member 121 easily.

When one conductor strip 2 has been inserted into the gap g between the suppressing portion 1221 of the lever 122 and the contact segment 1211 of the contact member 121, the user can push the handle 1222 of the lever 122 for allowing the lever 122 to be rotated and switched toward second position (as shown in FIG. 4B). During the process of switching the level 122 toward the second position, due to the conductor strip 2 has been inserted into the gap g, the suppressing portion 1221 continuously suppresses the conductor strip 2 and the carrying member 123 is slightly moved upwardly with respect to the contact member 121 or deformed when the suppressing portion 1221 is moved and disposed into the gap g. At this moment, the resilient member 124 is deformed and urges against the bottom plate 1233 of the carrying member 123 so as to limit the movement or deformation of the carrying member 123 and provide a suppressing force to assist the suppressing portion 1221 of the level 122 to clamp or secure the conductor strip 2. Therefore, the conductor strip 2 can be connected and secured with the conductor strip connection device 12 by the clamping method without using any auxiliary tool or screwdriver.

FIG. 5 is a schematic view showing the current-path arrangement module of the electrical connection mechanism of FIG. 2. As shown in FIGS. 2 and 5, the current-path arrangement module 13 is detachably connected with the conductor strip connection devices 12 and the electrical cables 3 and includes a plurality of electricity conveying elements 130, a plurality of electronic components 131 and a carrier 132. The electricity conveying elements 130 are separately disposed on one surface of the carrier 132 to form a plurality of electricity conveying paths. The electronic components 131 are disposed on the carrier 132, and each electronic component 131 is connected and secured to two adjacent electricity conveying elements 130 so as to form a current-path arrangement as required. In an embodiment, the carrier 132 is a supporting plate for supporting and mounting the electricity conveying elements 130 and the electronic components 131 thereon, the electricity conveying elements 130 are electrical conductive rails disposed on one surface of the carrier 132, and the electronic components 131 are bypass diodes. More preferably, there are four electrical conductive rails 130 a, 130 b, 130 c, 130 d and three bypass diodes 131 a, 131 b, 131 c mounted on one surface of the carrier 132. In an embodiment, each bypass diode 131 a, 131 b, 131 c has two terminals connected to two adjacent electrical conductive rails 130 a, 130 b, 130 c, 130 d of the current-path arrangement module 13. The electrical conductive rails 130 a, 130 b, 130 c, 130 d can be mounted on one surface of the carrier 132 by rails, embedding, engaging, locking or adhesive, and it is not limited thereto. The carrier 132 can be mounted on the bottom surface in the receptacle 103 of the base 101 of the housing 10 by screwing, locking or engaging, and it is not limited thereto. By using the current-path arrangement module 13, the bypass diodes 131 a, 131 b, 131 c can be replaced and maintained easily by replacing the current-path arrangement module 13 with another one when one or more bypass diodes 131 a, 131 b, 131 c is breakdown or failed.

In an embodiment, each of the electricity conveying elements 130 includes a main body 1301. The main body 1301 has plural engaging elements 1302. The carrier 132 has plural engaging elements 1321 for engaging with the engaging elements 1302 of the electricity conveying elements 130. Preferably, the engaging elements 1321 of the carrier 132 are hooks and the engaging elements 1302 of the electricity conveying elements 130 are engaging holes, and it is not limited thereto. The carrier 132 includes a plurality of supporting elements 1322 for supporting and securing the terminals of the electronic components 131 so that the terminals of the electronic components 131 can be coupled to the electricity conveying elements 130. Preferably, the supporting elements 1322 are protrusion rods with clamping arms. More preferably, the supporting element 1322 and the engaging element 1321 are integrally formed. When the terminals 1311 of the electronic components 131 are coupled to the electricity conveying elements 130, the terminals 1311 of the electronic components 131 can be inserted into the through holes 1305 formed on the main bodies 1301 of the electricity conveying elements 130.

The carrier 132 can be secured on the bottom surface of the receptacle 103 of the base 101. The carrier 132 further includes one or more securing element 1323 and the base 101 includes one or more securing element 101 b for fastening with the securing element 1323 of the carrier 132 so that the carrier 132 can be secured on the bottom surface of the receptacle 103 of the base 101. The main body 1301 of the electricity conveying element 130 further includes a first connection pad 1303 and a second connection pad 1304. The first connection pad 1303 of the electricity conveying element 130 is connected and fastened with the fixing segment 1212 of the conductor strip connection device 12 by fastening element, for example screw, and it is not limited thereto. The second connection pad 1304 of the electricity conveying element 130 is connected and fastened with a corresponding electrical cable 3 by fastening element, for example screw, and it is not limited thereto.

To sum up, the junction box of the present application is simple in construction, cost-effective, durable enough to withstand a wide range of environment conditions and easily be assembled, installed and maintained. In addition, the junction box of the present application includes a conductor strip connection device capable of assembling, fastening and coupling the thin conductor strip of the solar module to the junction box without using auxiliary tool or screwdriver and easily. Moreover, the junction box of the present invention can maintain a high-quality, reliable electrical connections between the components of a solar or photovoltaic system.

While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention needs not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures. 

What is claimed is:
 1. A junction box, comprising: a housing having an opening for introducing a plurality of conductor strips thereinto; and an electrical connection mechanism disposed in a receptacle of said housing and comprising: a plurality of conductor strip connection devices separately disposed on an inner surface of said housing for connecting to said conductor strips; and a current-path arrangement module comprising a plurality of electricity conveying elements and a plurality of electronic components, wherein said electricity conveying elements are connected with said conductor strip connection devices respectively, and each said electronic component is connected with two adjacent electricity conveying elements; wherein each of said conductor strip connection devices comprises: a contact member having a contact segment; a carrier member; and a lever pivotally connected with said carrier member and having a suppressing portion, said suppressing portion configured to cooperate with said contact segment of said contact member for disposing or removing said conductor strip when said lever is switched toward a first position and clamping and fastening said conductor strip when said lever is switched toward a second position.
 2. The junction box according to claim 1, wherein said contact member comprises: a fixing segment configured to connect with a corresponding electricity conveying device of said current-path arrangement module; and a stopper configured to limit a horizontal movement of said conductor strip.
 3. The junction box according to claim 2, wherein said stopper is a protrusion element extending upwardly from said contact segment.
 4. The junction box according to claim 1, wherein said conductor strip connection device further comprises a shaft, and said lever comprises: a handle; and a shaft receiving portion connected between said suppressing portion and said handle and having a receptacle for receiving said shaft.
 5. The junction box according to claim 4, wherein said suppressing portion of said lever is disposed between said shaft and said contact segment of said contact member.
 6. The junction box according to claim 4, wherein said carrying member comprises a first sidewall, a second sidewall, a bottom plate connected with said first sidewall and said second sidewall, and a receiving space defined by said first sidewall, said second sidewall and said bottom plate.
 7. The junction box according to claim 6, wherein said first sidewall and said second sidewall include a first through hole and a second through hole.
 8. The junction box according to claim 7, wherein said lever is pivotally connected with said carrying member by installing said shaft through said shaft receiving portion, said first through hole and said second through hole.
 9. The junction box according to claim 1, wherein said conductor strip connection device comprises a resilient member disposed between said contact segment of said contact member and said carrier member for urging against said carrier member.
 10. The junction box according to claim 9, wherein said resilient member comprises a connection segment, a first side segment and a second side segment opposite to said first side segment.
 11. The junction box according to claim 9, wherein said housing comprises a base comprising a plurality of holding devices for installing said conductor strip connection devices therein.
 12. The junction box according to claim 11, wherein said base of said housing includes a supporting element, said carrying member includes a first slot, and said resilient member includes a second slot corresponding to said first slot of said carrying member.
 13. The junction box according to claim 12, wherein said supporting element of said base is passing through said first slot and said second slot and contacts with a rear surface of said contact segment of said contact member.
 14. The junction box according to claim 9, wherein when said lever is switched toward said first position, said suppressing portion of said lever is apart from said contact segment of said contact member so that a gap is formed between said suppressing portion of said lever and said contact segment of said contact member.
 15. The junction box according to claim 9, wherein when said lever is switched toward said second position, said suppressing portion of said lever suppresses said conductor strip, and said resilient member is deformed and urges against said carrying member.
 16. The junction box according to claim 1, wherein said contact member is made of metal material.
 17. The junction box according to the claim 1, wherein said electronic components are bypass diodes.
 18. The junction box according to the claim 1, wherein said current-path arrangement module further comprises a carrier for supporting and mounting said electricity conveying elements and said electronic components thereon, and said electricity conveying elements are electrical conductive rails disposed on a surface of said carrier.
 19. A conductor strip connection device for a junction box of a solar module, comprising: a contact member having a contact segment for connecting to a conductor strip; a carrier member; and a lever pivotally connected with said carrier member and having a suppressing portion, said suppressing portion configured to cooperate with said contact segment of said contact member for disposing or removing said conductor strip when said lever is switched toward a first position and clamping and fastening said conductor strip when said lever is switched toward a second position.
 20. The conductor strip connection device according to claim 19, further comprising a resilient member disposed between said contact segment of said contact member and said carrier member for urging against said carrier member. 